JCB VMT860 TIER 3 VIBROMAX Service Repair Manual Instant Download

Service Manual VMT860 Tier 3 Service Manual - VMT860 Tier 3 Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section C - Electrics Section E - Hydraulics Section H - Steering Section K - Engine Section L - Vibration Publication No. 9813/0750 World Class Customer Support Copyright 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

Section 1 - General Information Notes: 1-0 1-0 9813/0750

Section 1 - General Information Contents Introduction About This Manual ..................................................................................... 1-1 Machine Model and Serial Number .......................................................1-1 Using the Service Manual .....................................................................1-1 Section Numbering ................................................................................1-1 Left Side, Right Side ..............................................................................1-2 Cross References ..................................................................................1-2 Identifying Your Machine ........................................................................... 1-3 Machine Identification Plate ..................................................................1-3 Page No. Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ....................................... 1-5 Introduction ............................................................................................1-5 Bolts and Screws ...................................................................................1-5 Hydraulic Connections ............................................................................... 1-9 'O' Ring Face Seal System ....................................................................1-9 'Torque Stop' Hose System .................................................................1-12 Service Tools Numerical List .......................................................................................... 1-13 Tool Detail Reference .............................................................................. 1-14 Section C - Electrics ............................................................................1-14 Section E - Hydraulics .........................................................................1-15 Service Consumables Sealing and Retaining Compounds ......................................................... 1-20 1-i 1-i

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Introduction About This Manual Machine Model and Serial Number Finally, please remember above all else safety must come first! This manual provides information for the following model(s) in the JCB machine range: Section Numbering T11-005 VMT 860 from SN 1778003 onwards. The manual is compiled in sections, the first three are numbered and contain information as follows: Using the Service Manual 1 General Information - includes torque settings and service tools. Care and Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc. Maintenance - includes service schedules and recommended lubricants for all the machine. T11-004 This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. 2 3 These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example: The illustrations in this publication are for guidance only. Where the machines differ, the text and/or the illustration will specify. A B Attachments Body and Framework, etc. General warnings in Section 2 are repeated throughout the manual, as well as specific warnings. Read all safety statements regularly, so you do not forget them. Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section. Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third. The manufacturer's policy is one of continuous improvement. The right to change the specification of the machine without notice is reserved. No responsibility will be accepted for discrepancies which may occur between specifications of the machine and the descriptions contained in this publication. 1-1 1-1 9813/0750

Introduction About This Manual Left Side, Right Side In this manual, 'left' A and 'right' B mean your left and right when you are seated correctly in the machine. B A Fig 1. Cross References T1-004_2 In this publication, page cross references are made by presenting the subject title printed in bold, italic and underlined. It is preceeded by the 'go to' symbol. The number of the page upon which the subject begins, is indicated within the brackets. For example: K K Cross References ( T T 2). 1-2 1-2 9813/0750

Introduction Identifying Your Machine Identifying Your Machine Machine Identification Plate Your machine has an identification plate mounted as shown. K K Fig 2. ( T T 3). The machine and engine serial numbers can help identify exactly the type of equipment you have. Fig 2. 1-3 1-3 9813/0750

Introduction Identifying Your Machine Page left intentionally blank 1-4 1-4 9813/0750

Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Torque Settings Zinc Plated Fasteners and Dacromet Fasteners T11-002 Introduction Bolts and Screws Some external fasteners on JCB machines are manufactured using an improved type of corrosion resistant finish. This type of finish is called Dacromet and replaces the original Zinc and Yellow Plating used on earlier machines. Use the following torque setting tables only where no torque setting is specified in the text. Note: Dacromet fasteners are lubricated as part of the plating process, do not lubricate. The two types of fasteners can be readily identified by colour and part number suffix. K K Table 1. Fastener Types ( T T 5). Torque settings are given for the following conditions: Condition 1 Table 1. Fastener Types Colour Un-lubricated fasteners Zinc fasteners Yellow plated fasteners Fastener Type Zinc and Yellow Dacromet Part No. Suffix Golden finish 'Z' (e.g. 1315/3712Z) Condition 2 Mottled silver finish 'D' (e.g. 1315/3712D) Zinc flake (Dacromet) fasteners Lubricated zinc and yellow plated fasteners Where there is a natural lubrication. For example, cast iron components Note: As the Dacromet fasteners have a lower torque setting than the Zinc and Yellow fasteners, the torque figures used must be relevant to the type of fastener. Note: A Dacromet bolt should not be used in conjunction with a Zinc or Yellow plated nut, as this could change the torque characteristics of the torque setting further. For the same reason, a Dacromet nut should not be used with a Zinc or Yellow plated bolt. Verbus Ripp Bolts Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification. Fig 3. Note: Dacromet bolts, due to their high corrosion resistance are used in areas where rust could occur. Dacromet bolts are only used for external applications. They are not used in applications such as gearbox or engine joint seams or internal applications. Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings. 1-5 1-5 9813/0750

Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 2. Torque Settings - UNF Grade 'S' Fasteners Hexagon (A/F) in. Nm 7/16 11.2 1/2 22.3 9/16 40.0 5/8 64.0 3/4 98.00 13/16 140.0 15/16 196.0 1 1/8 343.0 1 15/16 547.0 1 1/2 814.0 1 7/8 1181.0 2 1/4 1646.0 Bolt Size Condition 1 kgf m 1.1 2.3 4.1 6.5 10.0 14.3 20.0 35.0 55.8 83.0 120.4 167.8 Condition 2 kgf m 1.0 2.0 3.7 5.8 9.0 12.8 18.0 31.5 50.2 74.6 108.4 151.0 in. 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 mm 6.3 7.9 9.5 11.1 12.7 14.3 15.9 19.0 22.2 25.4 31.7 38.1 lbf ft 8.3 16.4 29.5 47.2 72.3 103.2 144.6 253.0 403.4 600.4 871.1 1214.0 Nm 10.0 20.0 36.0 57.0 88.0 126.0 177.0 309.0 492.0 732.0 1063.0 1481.0 lbf ft 7.4 14.7 26.5 42.0 64.9 92.9 130.5 227.9 362.9 539.9 784.0 1092.3 Table 3. Torque Settings - Metric Grade 8.8 Fasteners Hexagon (A/F) Bolt Size Condition 1 Condition 2 ISO Metric Thread M5 M6 M8 M10 M12 M16 M20 M24 M30 M36 mm 5 6 8 10 12 16 20 24 30 36 mm 8 10 13 17 19 24 30 36 46 55 Nm 5.8 9.9 24.0 47.0 83.0 205.0 400.0 690.0 1372.0 2399.0 kgf m 0.6 1.0 2.4 4.8 8.5 20.9 40.8 70.4 139.9 244.6 lbf ft 4.3 7.3 17.7 34.7 61.2 151.2 295.0 508.9 1011.9 1769.4 Nm 5.2 9.0 22.0 43.0 74.0 184.0 360.0 621.0 1235.0 2159.0 kgf m 0.5 0.9 2.2 4.4 7.5 18.8 36.7 63.3 125.9 220.0 lbf ft 3.8 6.6 16.2 31.7 54.6 135.7 265.5 458.0 910.9 1592.4 1-6 1-6 9813/0750

Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 4. Metric Grade 10.9 Fasteners Hexagon (A/F) Bolt Size Condition 1 Condition 2 ISO Metric Thread M5 M6 M8 M10 M12 M16 M20 M24 M30 M36 mm 5 6 8 10 12 16 20 24 30 36 mm 8 10 13 17 19 24 30 36 46 55 Nm 8.1 13.9 34.0 67.0 116.0 288.0 562.0 971.0 1930.0 3374.0 kgf m 0.8 1.4 3.5 6.8 11.8 29.4 57.3 99.0 196.8 344.0 lbf ft 6.0 10.2 25.0 49.4 85.5 212.4 414.5 716.9 1423.5 2488.5 Nm 7.3 12.5 30.0 60.0 104.0 259.0 506.0 874.0 1737.0 3036.0 kgf m 0.7 1.3 3.0 6.1 10.6 26.4 51.6 89.1 177.1 309.6 lbf ft 5.4 9.2 22.1 44.2 76.7 191.0 373.2 644.6 1281.1 2239.2 Table 5. Metric Grade 12.9 Fasteners Hexagon (A/F) Bolt Size Condition 1 Condition 2 ISO Metric Thread M5 M6 M8 M10 M12 M16 M20 M24 M30 M36 mm 5 6 8 10 12 16 20 24 30 36 mm 8 10 13 17 19 24 30 36 46 55 Nm 9.8 16.6 40.0 80.0 139.0 345.0 674.0 1165.0 2316.0 4049.0 kgf m 1.0 1.7 4.1 8.1 14.2 35.2 68.7 118.8 236.2 412.9 lbf ft 7.2 12.2 29.5 59.0 102.5 254.4 497.1 859.2 1708.2 2986.4 Nm 8.8 15.0 36.0 72.0 125.0 311.0 607.0 1048.0 2084.0 3644.0 kgf m 0.9 1.5 3.7 7.3 12.7 31.7 61.9 106.9 212.5 371.6 lbf ft 6.5 11.1 26.5 53.1 92.2 229.4 447.7 773.0 1537.1 2687.7 1-7 1-7 9813/0750

Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 6. Torque Settings - Rivet Nut Bolts/Screws Bolt Size ISO Metric Thread mm M3 3 M4 4 M5 5 M6 6 M8 8 M10 10 M12 12 Nm 1.2 3.0 6.0 10.0 24.0 48.0 82.0 kgf m 0.1 0.3 0.6 1.0 2.5 4.9 8.4 lbf ft 0.9 2.0 4.5 7.5 18.0 35.5 60.5 Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc) Bolt Size ISO Metric Thread M3 2.0 M4 6.0 M5 11.0 M6 19.0 M8 46.0 M10 91.0 M12 159.0 M16 395.0 M18 550.0 M20 770.0 M24 1332.0 Nm kgf m 0.2 0.6 1.1 1.9 4.7 9.3 16.2 40.0 56.0 79.0 136.0 lbf ft 1.5 4.5 8.0 14.0 34.0 67.0 117.0 292.0 406.0 568.0 983.0 1-8 1-8 9813/0750

Torque Settings Hydraulic Connections Hydraulic Connections T11-003 'O' Ring Face Seal System Adaptors Screwed into Valve Blocks Adaptor screwed into valve blocks, seal onto an 'O' ring which is compressed into a 45 seat machined into the face of the tapped port. Table 8. Torque Settings - BSP Adaptors BSP Adaptor Size in. mm 1/4 19.0 3/8 22.0 1/2 27.0 5/8 30.0 3/4 32.0 1 38.0 1 1/4 50.0 Hexagon (A/F) Nm 18.0 31.0 49.0 60.0 81.0 129.0 206.0 kgf m 1.8 3.2 5.0 6.1 8.2 13.1 21.0 lbf ft 13.0 23.0 36.0 44.0 60.0 95.0 152.0 Table 9. Torque Settings - SAE Connections SAE Port Thread Size mm 7/16 - 20 15.9 9/16 - 18 19.1 3/4 - 16 22.2 7/8 - 14 27.0 1 1/16 - 12 31.8 1 5/16 - 12 38.1 1 5/8 47.6 Hexagon (A/F) SAE Tube Size 4 6 8 10 12 16 20 Nm kgf m 2.0 - 2.8 4.7 - 5.5 9.7 - 10.7 13.2 - 14.3 19.4 - 21.4 29.6 - 31.6 28.5 - 38.7 lbf ft 20.0 - 28.0 46.0 - 54.0 95.0 - 105.0 130.0 - 140.0 190.0 - 210.0 290.0 - 310.0 280.0 - 380.0 16.5 - 18.5 34.0 - 40.0 69.0 - 77.0 96.0 - 104.0 141.0 - 155.0 216.0 - 230.0 210.0 - 280.0 1-9 1-9 9813/0750

Torque Settings Hydraulic Connections Hoses Screwed into Adaptors Fig 4. Hoses 4-B screwed into adaptors 4-A seal onto an `O' ring 4-C which is compressed into a 45 seat machined into the face of the adaptor port. Note: Dimension 4-D will vary depending upon the torque applied. Table 10. BSP Hose - Torque Settings Hexagon (A/F) mm 14.0 14.0 - 16.00 19.0 24.0 - 27.0 22.0 33.0 - 40.0 27.0 44.0 - 50.0 30.0 58.0 - 65.0 32.0 84.0 - 92.0 38.0 115.0 - 126.0 50.0 189.0 - 200.0 55.0 244.0 - 260.0 BSP Hose Size in. 1/8 1/4 3/8 1/2 5/8 3/4 1 1 1/4 1 1/2 Nm kgf m 1.4 - 1.6 2.4 - 2.7 3.4 - 4.1 4.5 - 5.1 5.9 - 6.6 8.6 - 9.4 11.7 - 12.8 19.3 - 20.4 24.9 - 26.5 lbf ft 10.3 - 11.8 17.7 - 19.9 24.3 - 29.5 32.4 - 36.9 42.8 - 47.9 61.9 - 67.8 84.8 - 92.9 139.4 - 147.5 180.0 - 191.8 1-10 1-10 9813/0750

Torque Settings Hydraulic Connections Adaptors into Component Connections with Bonded Washers Table 11. BSP Adaptors with Bonded Washers - Torque Settings BSP Size Nm in. 1/8 20.0 1/4 34.0 3/8 75.0 1/2 102.0 5/8 122.0 3/4 183.0 1 203.0 1 1/4 305.0 1 1/2 305.0 kgf m 2.1 3.4 7.6 10.3 12.4 18.7 20.7 31.0 31.0 lbf ft 15.0 25.0 55.0 75.0 90.0 135.0 150.0 225.0 225.0 1-11 1-11 9813/0750

Torque Settings Hydraulic Connections 'Torque Stop' Hose System Fig 5. `Torque Stop' Hoses 5-B screwed into adaptors 5-A seal onto an 'O' ring 5-C which is compressed into a 45 seat machined in the face of the adaptor port. To prevent the 'O' ring being damages as a result of over tightening, 'Torque Stop' Hoses have an additional shoulder 5-D, which acts as a physical stop. Note: Minimum dimension 5-E fixed by shoulder 5-D. Table 12. BSP `Torque Stop' Hose - Torque Settings BSP Hose Size Hexagon (A/F) in. mm 1/8 14.0 1/4 19.0 3/8 22.0 1/2 27.0 5/8 30.0 3/4 32.0 1 38.0 1 1/4 50.0 1 1/2 55.0 Nm 14.0 27.0 40.0 55.0 65.0 95.0 120.0 189.0 244.0 kgf m 1.4 2.7 4.1 5.6 6.6 9.7 12.2 19.3 24.9 lbf ft 10.0 20.0 30.0 40.0 48.0 70.0 89.0 140.0 180.0 1-12 1-12 9813/0750

Service Tools Numerical List The tools listed in the table are special tools required for carrying out the procedures described in this manual. These tools are available from JCB Service. details of all tools, including the content of kits and sets, refer to Tool Detail Reference, Section 1. Note: Tools other than those listed will be required. It is expected that such general tools will be available in any well equipped workshop or be available locally from any good tool supplier. Some tools are available as kits or sets, the part numbers for parts within such kits or sets are not listed here. For full Part Number - - - - - - Description See Section E E E E E E Bonded Washers - see Tool Detail Reference (Section 1) for content Female Cone Blanking Caps - see Tool Detail Reference (Section 1) for content Female Connectors - see Tool Detail Reference (Section 1) for content Hydraulic Flow Test Equipment - see Tool Detail Reference (Section 1) for content Male Adapters - BSP x BSP - see Tool Detail Reference (Section 1) for content Male Adapters - BSP x NPT (USA only) - see Tool Detail Reference (Section 1) for content Male Cone Blanking Caps - see Tool Detail Reference (Section 1) for content Pressure Test Points - Adaptors - see Tool Detail Reference (Section 1) for content Pressure Test Points - 'T' Adaptors - see Tool Detail Reference (Section 1) for content Hydraulic Circuit Pressure Test Kit - see Tool Detail Reference (Section 1) for content Hose Gauge Gauge Digital Tachometer Hyd. Oil Temperature Probe Fluke Meter Gauge Connector Vibromax male to JCB female threaded adaptor JCB male to Vibromax female threaded adaptor Frequency and Vibration Measuring Tool 100 amp Shunt E E E E E E E C C C E E E E E - - - 892/00253 892/00254 892/00279 892/00280 892/00284 892/00285 892/00298 892/00346 892/00347 892/01246 892/01247 892/12345 892/00285 C 1-13 1-13 9813/0750

Service Tools Tool Detail Reference Tool Detail Reference Section C - Electrics Note: Not all service tools are illustrated. Fig 6. 892/00298 Fluke Meter Fig 7. 892/00285 Hydraulic Temperature Probe Fig 8. 892/00284 Venture Microtach Digital Tachometer 1-14 1-14 9813/0750

Service Tools Tool Detail Reference Section E - Hydraulics Note: Not all service tools are illustrated. Male Adapters - BSP x BSP 3/8 in. x 1/4 in. 3/8 in. x 3/8 in. 3/8 in. x 3/8 in. taper 1/2 in. x 1/4 in. 1/2 in. x 3/8 in. 1/2 in. x 1/2 in. 5/8 in. x 1/2 in. 3/4 in. x 3/8 in. 3/4 in. x 1/2 in. 3/4 in. x 3/4 in. 3/4 in. x 1 in. 3/4 in. x 1.1/4 in. 1 in. x 1.1/4 in. 1606/2052 1604/0003A 892/00071 1606/0004 1606/0007A 1604/0004A 1606/0017 1606/0008 1606/0009 1604/2055 1606/0012 1606/0014 1606/0015 Fig 9. Male Adaptors Male Adapters - BSP x NPT (USA only) 3/8 in. x 1/4 in. 1/2 in. x 1/4 in. 3/8 in. x 3/8 in. 1/2 in. x 3/8 in. 816/00439 816/00440 816/15007A 816/15008 892/00255 892/00256 892/00257 892/00258 816/15118 892/00259 892/00260 892/00261 1/4 in. BSP x Test Point 3/8 in. BSP x Test Point 1/2 in. BSP x Test Point 5/8 in. BSP x Test Point 3/4 in. BSP x Test Point 1 in BSP x Test Point 1.1/4 in. BSP x Test Point 5/8 in. UNF x Test Point Fig 10. Pressure Test Adapters 816/55045 816/55038 816/55040 892/00263 892/00264 892/00265 892/00266 892/00267 1/4 in. M BSP x 1/4 in. F BSP x Test Point 3/8 in. M BSP x 3/8 in. F BSP x Test Point 1/2 in. M BSP x 1/2 in. F BSP x Test Point 5/8 in. M BSP x 5/8 in. F BSP x Test Point 3/4 in. M BSP x 3/4 in. F BSP x Test Point 1 in. M BSP x 1 in. F BSP x Test Point 1.1/4 in. M BSP x 1.1/4 in. F BSP x Test Point 1.1/4 in. M BSP x 1.1/2 in. F BSP x Test Point Fig 11. Pressure Test 'T' Adapters 1-15 1-15 9813/0750

Service Tools Tool Detail Reference 3/8 in. BSP (A) x 1/4 in. BSP (B) 1/2 in. BSP (A) x 1/4 in. BSP (B) 5/8 in. BSP (A) x 1/4 in. BSP (B) 3/4 in. BSP (A) x 1/4 in. BSP (B) 1 in. BSP (A) x 1/4 in. BSP (B) 1/2 in. BSP (A) x 1/2 in. BSP (B) 3/4 in. BSP (A) x 3/4 in. BSP (B) 1 in. BSP (A) x 1 in. BSP (B) 892/00047 892/00048 892/00049 816/50043 892/00051 816/50005 816/60096 816/00017 Fig 12. 'T' Adapters 892/00055A 892/00056A 892/00057 892/00058A 892/00059A 892/00060 1/4 in. BSP 3/8 in. BSP 1/2 in. BSP 5/8 in. BSP 3/4 in. BSP 1 in. BSP Fig 13. Female Blanking Caps 816/90045 816/00189A 816/00190A 816/90022 816/90274 816/90205 1/4 in. BSP 3/8 in. BSP 1/2 in. BSP 5/8 in. BSP 3/4 in. BSP 1 in. BSP Fig 14. Male Cone Blanking Caps 892/00074 892/00075 892/00076 892/00077 3/8 in. BSP x 3/8 in. BSP 1/2 in. BSP x 1/2 in. BSP 5/8 in. BSP x 5/8 in. BSP 3/4 in. BSP x 3/4 in. BSP Fig 15. Female Connectors 1406/0011 1406/0018 1406/0014 1406/0021 1406/0029 1/4 in. BSP 1/2 in. BSP 5/8 in. BSP 3/4 in. BSP 1.1/4 in. BSP Fig 16. Bonded Washers 1-16 1-16 9813/0750

Service Tools Tool Detail Reference 892/00268 Flow Monitoring Unit Note: No longer available, refer to 998/11046 JCB ServiceMaster Flow Test Kit. K K Fig 18. ( T T 17). 892/00269 892/00273 892/00293 892/00270 1406/0021 1604/0006A 1612/2054 892/00271 892/00272 816/20008 892/00275 892/00276 892/00277 1606/0015 892/00078 1604/0008 1606/0012 816/20013 Sensor Head 0 - 100 l/min (0 - 22 UK gal/min) Sensor Head 0 - 380 l/min (0 - 85.5 UK gal/min) Connector Pipe Load Valve Bonded Washer Adapter 3/4 in M x 3/4 in M BSP Adapter 3/4 in F x 3/4 in M BSP Adapter 3/4 in F x 5/8 in M BSP Adapter 5/8 in F x 3/4 in M BSP Adapter 3/4 in F x 1/2 in M BSP Adapter 1/2 in F x 3/4 in M BSP Adapter 3/4 in F x 3/8 in M BSP Adapter 3/8 in F x 3/4 in M BSP Adapter 1.1/4 in M BSP x 1 in M BSP Connector 1 in F x 1 in F BSP Adapter 1 in M x 1 in M BSP Adapter 1 in M x 3/4 in M BSP Adapter 3/4 in F x 1 in M BSP Fig 17. Flow Test Equipment 998/11047 998/11048 600 LPM Flow Turbine with Loading Valve 1-7/8" UNF x1 - 1/4" BSP Flow Block Adaptors x2 Carrying Case for Flow Test Kit Temperature Sensor (125 C Max) 998/11049 998/11050 Fig 18. 998/11046 JCB ServiceMaster Flow Test Kit 1-17 1-17 9813/0750

Service Tools Tool Detail Reference 892/00201 Note: No longer available, refer to 998/11051 JCB ServiceMaster Digital Hydraulic Datalogger Pressure Test Kit. K K Fig 20. ( T T 18). Replacement Gauge 0-20 bar (0-300 lbf/in2) 892/00202 892/00203 892/00254 993/69800 Replacement Gauge 0-40 bar (0-600 lbf/in2) Replacement Gauge 0-400 bar (0-6000 lbf/in2) Replacement Hose Seal Kit for 892/00254 (can also be used with probe 892/00706) Test Probe Connector - Hose to gauge 1 2 3 892/00706 892/00347 Fig 19. 892/ 00253 Hydraulic Circuit Pressure Test Kit 998/11052 998/11053 998/11054 998/11055 998/11056 998/11057 Hand Held 4-Channel ServiceMaster Unit SensoWin Software Kit and PC Cable Equiment Case SCC-750 0-600 Bar Pressure Transduce x2 0-100 Bar pressureTransducer x2 RPM Tachometer (includes fixed cable, 2 meters) 5 Meter Connecting Cable M16 Metric Adaptors for Test Points x4 400mm Test Hose 90 HSP to M16 x2 400mm Test Hose Straight HSP to M16 x2 998/11058 998/11059 998/11060 998/11061 Fig 20. 998/11051 JCB ServiceMaster Digital Hydraulic Datalogger Pressure Test Kit 892/00280 892/00279 892/00346 892/00347 892/00254 Pressure Gauge 0-600 bar (0-9000 lbf/in2) Pressure Gauge 0-400 bar (0-6000 lbf/in2) Pressure Gauge 0-70 bar (0-1000 lbf/in2) Connector Hose Fig 21. Hydraulic Circuit Test Gauges and Connections 1-18 1-18 9813/0750

Service Tools Tool Detail Reference Fig 22. Adaptor (item A) Description 892/01247 JCB male to Vibromax female threaded adaptor - Connects JCB female test hose to male Vibromax test point 892/01246 Vibromax male to JCB female threaded adaptor - Connects Vibromax female test hose to JCB male test point Item A Part No Qty a/r B a/r Note: In order to use JCB test hoses and gauges on JCB Vibromax machines (and where applicable, other manufacturers machines fitted with M16 X2mm test points) a special adaptor A is required. For JCB Vibromax dealers or customers that already have JCB Vibromax compatible test hoses a `special adaptor' B (not shown) will be required to connect to JCB test points Fig 23. 892/12345 Frequency and Vibration Measuring Tool Allows the service engineer to measure the frequency of the vibrating drum (it will also measure engine speed on any type of machinery). 1-19 1-19 9813/0750

Service Consumables Sealing and Retaining Compounds Service Consumables Sealing and Retaining Compounds T11-001_4 Table 13. Type JCB Multi-Gasket Description A medium strength sealant suitable for all sizes of gasket flanges, and for hydraulic fittings of 25-65 mm diameter. A high strength locking fluid for use with threaded components. Gasketing for all sizes of flange where the strength of the joint is important. For all retaining parts which are unlikely to be dismantled. Part No. 4102/1212 Quantity 50 ml JCB High Strength Threadlocker 4102/0551 50 ml JCB Retainer (High Strength) 4101/0601 4101/0651 4101/0250 4101/0251 10 ml 50 ml 10 ml 50 ml JCB Threadlocker and Sealer A medium strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter. A high strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter. A medium strength thread sealing compound. A cleaning primer which speeds the curing rate of anaerobic products. JCB Threadlocker and Sealer (High Strength) 4101/0550 4101/0552 10 ml 200 ml JCB Threadseal JCB Activator 4102/1951 4104/0251 4104/0253 4104/1557 50 ml 200 ml (Aerosol) 1 ltr (Bottle) 400 ml (Aerosol) JCB Cleaner/Degreaser For degreasing components prior to use of anaerobic adhesives and sealants. For one pane of glass; comprises of: Direct Glazing Kit 993/55700 1 x Ultra Fast Adhesive (310 ml) 1 x Active Wipe 205 (30 ml) 1 x Black Primer 206J (30 ml) plus applicator nozzle etc. For direct glazing. For direct glazing. For direct glazing. To seal butt jointed glass. To seal plastic to metal joints. To finish exposed edges of laminated glass. Ultra Fast Adhesive Active Wipe 205 Black Primer 206J Clear Silicone Sealant Plastic to Metal Bonder Black Polyurethane Sealant 4103/2109 4104/1203 4201/4906 4102/0901 4103/0956 4102/2309 310 ml 250 ml 30 ml 50 g 310 ml 1-20 1-20 9813/0750

Service Consumables Sealing and Retaining Compounds Page left intentionally blank 1-21 1-21 9813/0750

Section 2 - Care and Safety Notes: 2-0 2-0 9813/0750

Section 2 - Care and Safety Contents Page No. Safety Notices Important Information ................................................................................ 2-1 Safety Check List ....................................................................................... 2-2 Safety Labels ........................................................................................... 2-12 2-i 2-i

Safety Notices Important Information T1-042 The Operator Manual Safety Warnings Do not operate the machine without an Operator Manual, or if there is anything on the machine you do not understand. This safety alert system identifies important safety messages in this manual. When you see this symbol, be alert, your safety is involved, carefuly read the message that follows, and inform other operators. Treat the Operator Manual as part of the machine. Keep it clean and in good condition. Replace the Operator Manual immediately if it is lost, damaged or becomes unreadable. In this publication and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below. !MDANGER Denotes an extreme hazard exists. If proper precautions are not taken, it is highly probable that the operator (or others) could be killed or seriously injured. INT-1-2-1 !MWARNING Denotes a hazard exists. If proper precautions are not taken, the operator (or others) could be killed or seriously injured. INT-1-2-2 !MCAUTION Denotes a reminder of safety practices. Failure to follow these safety practices could result in injury to the operator (or others) and possible damage to the machine. INT-1-2-3 1-1 1-1 9813/0750

Safety Notices Safety Check List Safety Check List Safety - Yours and Others General Safety INT-1-3-1_3 T1-043 !MWARNING All machinery can be hazardous. When a machine is correctly operated and properly maintained, it is a safe machine to work with. But when it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others. Care and Alertness All the time you are working with or on the machine, take care and stay alert. Always be careful. Always be alert for hazards. In this manual and on the machine you will find warning messages. Read and understand them. They tell you of potential hazards and how to avoid them. If you do not fully understand the warning messages, ask your employer or JCB distributor to explain them. INT-1-3-5 !MWARNING Clothing You can be injured if you do not wear the proper clothing. Loose clothing can get caught in the machinery. Wear protective clothing to suit the job. Examples of protective clothing are: a hard hat, safety shoes, safety glasses, a well fitting overall, ear- protectors and industrial gloves. Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained. Remove rings, watches and personal jewellery. But safety is not just a matter of responding to the warnings. All the time you are working on or with the machine you must be thinking what hazards there might be and how to avoid them. Do not work with the machine until you are sure that you can control it. Do not start any job until you are sure that you and those around you will be safe. INT-1-3-6_2 !MWARNING If you are unsure of anything, about the machine or the job, ask someone who knows. Do not assume anything. Alcohol and Drugs It is extremely dangerous to operate machinery when under the influence of alcohol or drugs. Do not consume alcoholic drinks or take drugs before or while operating the machine or attachments. Be aware of medicines which can cause drowsiness. Remember BE CAREFUL BE ALERT INT-1-3-9_2 BE SAFE !MWARNING Feeling Unwell Do not attempt to operate the machine if you are feeling unwell. By doing so you could be a danger to yourself and those you work with. 8-1-2-4 1-2 1-2 9813/0750

Safety Notices Safety Check List !MWARNING !MWARNING Mobile Phones Machine Modifications Switch off your mobile phone before entering an area with a potentially explosive atmosphere. Sparks in such an area could cause an explosion or fire resulting in death or serious injury. This machine is manufactured in compliance with legislative and other requirements. It should not be altered in any way which could affect or invalidate any of these requirements. For advice consult your JCB Distributor. Switch off and do not use your mobile phone when refuelling the machine. INT-1-3-10_2 INT-3-3-9 !MWARNING Lifting Equipment You can be injured if you use incorrect or faulty lifting equipment. You must identify the weight of the item to be lifted then choose lifting equipment that is strong enough and suitable for the job. Make sure that lifting equipment is in good condition and complies with all local regulations. INT-1-3-7_2 !MWARNING Raised Equipment Never walk or work under raised equipment unless it is supported by a mechanical device. Equipment which is supported only by a hydraulic device can drop and injure you if the hydraulic system fails or if the control is operated (even with the engine stopped). Make sure that no-one goes near the machine while you install or remove the mechanical device. 13-2-3-7_3 !MWARNING Raised Machine NEVER position yourself or any part of your body under a raised machine which is not properly supported. If the machine moves unexpectedly you could become trapped and suffer serious injury or be killed. INT-3-3-7_1 !MDANGER Lightning Lightning can kill you. Do not use the machine if there is lightning in your area. 5-1-1-2 1-3 1-3 9813/0750

Safety Notices Safety Check List !MWARNING Operating Safety Communications !MWARNING Bad communications can cause accidents. Keep people around you informed of what you will be doing. If you will be working with other people, make sure any hand signals that may be used are understood by everybody. Work sites can be noisy, do not rely on spoken commands. Machine Condition A defective machine can injure you or others. Do not operate a machine which is defective or has missing parts. Make sure the maintenance procedures in this manual are completed before using the machine. INT-2-2-3 INT-2-1-2_2 !MWARNING !MWARNING Parking Machine Limits An incorrectly parked machine can move without an operator. Follow the instructions in the Operator Manual to park the machine correctly. Operating the machine beyond its design limits can damage the machine, it can also be dangerous. Do not operate the machine outside its limits. Do not try to upgrade the machine performance with unapproved modifications. INT-2-2-4_2 !MWARNING INT-2-1-4 Banks and Trenches !MWARNING Banked material and trenches can collapse. Do not work or drive too close to banks and trenches where there is danger of collapse. Engine/Steering Failure If the engine or steering fails, stop the machine as quickly as possible. Do not operate the machine until the fault has been corrected. INT-2-2-5 !MWARNING INT-2-1-5 Ramps and Trailers !MWARNING Water, mud, ice, grease and oil on ramps or trailers can cause serious accidents. Make sure ramps and trailers are clean before driving onto them. Use extreme caution when driving onto ramps and trailers. Exhaust Gases Breathing the machine exhaust gases can harm and possibly kill you. Do not operate the machine in closed spaces without making sure there is good ventilation. If possible, fit an exhaust extension. If you begin to feel drowsy, stop the machine at once and get into fresh air. INT-2-2-6 !MWARNING Safety Barriers INT-2-1-10_2 Unguarded machines in public places can be dangerous. In public places, or where your visibility is reduced, place barriers around the work area to keep people away. !MWARNING Work Sites Work sites can be hazardous. Inspect the site before working on it. Look for potholes, weak ground, hidden rocks etc. Check for utilities such as electric cables (overhead and underground), gas and water pipes etc. Mark the positions of the underground cables and pipes. Make sure that you have enough clearance beneath overhead cables and structures. INT-2-2-8 !MDANGER Sparks Explosions and fire can be caused by sparks from the exhaust or the electrical system. Do not use the machine in closed areas where there is flammable material, vapour or dust. INT-2-2-1 INT-2-2-10 1-4 1-4 9813/0750

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Safety Notices Safety Check List !MWARNING !MWARNING Hazardous Atmospheres Visibility This machine is designed for use in normal out door atmospheric conditions. It should not be used in an enclosed area without adequate ventilation. Do not use the machine in atmosphere, i.e. combustible vapours, gas or dust, without first consulting your JCB Distributor. Accidents can be caused by working in poor visibility. Use your lights to improve visibility. Keep the road lights, windows and mirrors clean. a potentially explosive Do not operate the machine if you cannot see clearly. 5-1-4-7 INT-2-1-14 !MWARNING !MCAUTION Electrical Power Cables Regulations You could be electrocuted or badly burned if you get the machine or its attachments too close to electrical power cables. Obey all laws, work site and local regulations which affect you and your machine. INT-1-3-3 You are strongly advised to make sure that the safety arrangements on site comply with the local laws and regulations concerning work near electric power lines. !MWARNING Practice Before you start using the machine, check with your electricity supplier if there are any buried power cables on the site. You or others can be killed or seriously injured if you do unfamiliar operations without first practising them. Practise away from the work site on a clear area. Keep other people away. Do not perform new operations until you are sure you can do them safely. There is a minimum clearance required for working beneath overhead power cables. You must obtain details from your local electricity supplier. INT-2-1-1 !MWARNING 2-2-5-4 !MCAUTION Airborne particles of light combustible material such as straw, grass, wood shavings, etc. must not be allowed to accumulate within the engine compartment or in the propshaft guards (when fitted). Inspect these areas frequently and clean at the beginning of each work shift or more often if required. Before opening the engine cover, ensure that the top is clear of debris. If you have an attachment which is not covered in the Operator Manual do not install it, use it or remove it until you have obtained, read and understood the pertinent information. Install attachments only on the machines for which they were designed. 5-5-1-1_2 5-3-1-12_3 !MWARNING !MWARNING Use only the JCB approved attachments that are specified for your machine. Operating with non- specified attachments can overload the machine, causing possible damage and machine instability which could result in injury to yourself or others. Keep the machine controls clean and dry. Your hands and feet could slide off slippery controls. If that happens you could lose control of the machine. 2-2-3-6 The use of non-approved attachments could invalidate your warranty. 2-4-5-2_1 1-5 1-5 9813/0750

Safety Notices Safety Check List !MDANGER !MWARNING Working Platform Fires Using the machine as a working platform is hazardous; you can fall off and be killed or injured. Never use the machine as a working platform. If your machine is equipped with a fire extinguisher, make sure it is checked regularly. Keep it in the correct machine location until you need to use it. 5-1-5-9 Do not use water to put out a machine fire, you could spread an oil fire or get a shock from an electrical fire. Use carbon dioxide, dry extinguishers. Contact your nearest fire department as quickly as possible. Firefighters should use self- contained breathing apparatus. !MWARNING chemical or foam The engine has exposed rotating parts. Switch OFF the engine before working in the engine compartment. Do not use the machine with the engine cover open. INT-3-2-7_2 5-2-6-5 !MWARNING !MWARNING Should the machine start to roll over, you can be crushed if you try to leave the cab. If the machine starts to roll over, do not try and jump from the cab. Stay in the cab, with your seat belt fastened. You could be killed or seriously injured if you operate a machine with a damaged or missing ROPS/FOPS. If the Roll Over Protection Structure (ROPS)/Falling Objects Protection Structure (FOPS) has been in an accident, do not use the machine until the structure has been renewed. Modifications and repairs that are not approved by the manufacturer may be dangerous and will invalidate the ROPS/FOPS certification. INT-2-1-12 !MWARNING Entering/Leaving INT-2-1-9_6 Entering or leaving the cab or canopy must only be made where steps and handrails are provided. Always face the machine when entering and leaving. Make sure the step(s), handrails and your boot soles are clean and dry. Do not jump from the machine. Do not use the machine controls as handholds, use the handrails. !MWARNING Reversing Reversing at high speeds can cause accidents. Do not reverse in a high gear with full throttle. Always drive at a safe speed to suit working conditions. INT-2-1-7_1 INT-2-2-9_1 !MWARNING !MWARNING Hillsides Controls Operating the machine on hillsides can be dangerous if proper precautions are not taken. Ground conditions can be changed by rain, snow, ice etc. Check the site carefully. Operate at a suitable slow speed on hillsides. You or others can be killed or seriously injured if you operate the control levers from outside the machine. Operate the control levers only when you are correctly seated in the machine. 0179 15-1-1-1 !MCAUTION !MWARNING Passengers Hill sides Passengers in or on the machine can cause accidents. Do not carry passengers. Operating on hillsides can be dangerous, especially moving across a slope. If the slope is too steep, your machine could roll over. INT-2-2-2_1 15-1-1-2 1-6 1-6 9813/0750

Safety Notices Safety Check List !MWARNING Maintenance Safety Slopes !MWARNING When travelling on a slope, drive slowly and keep the roller up hill of the machine. This will increase stability. Communications Bad communications can cause accidents. If two or more people are working on the machine, make sure each is aware of what the others are doing. Before starting the engine make sure the others are clear of the danger areas; examples of danger areas are: the rotating blades and belt on the engine, the attachments and linkages, and anywhere beneath or behind the machine. People can be killed or injured if these precautions are not taken. 15-1-1-11 INT-3-1-5 !MWARNING Repairs If your machine does not function correctly in any way, get it repaired straight away. Neglect of necessary repairs could result in an accident or affect your health. Do not try to do repairs or any other type of maintenance work you do not understand. To avoid injury and/or damage get the work done by a specialist engineer. GEN-1-5_2 !MWARNING Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out. Use a soft faced hammer or copper pin to remove and fit metal pins. Always wear safety glasses. INT-3-1-3_2 !MWARNING Electrical Circuits Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage. INT-3-1-4 1-7 1-7 9813/0750

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